Cable connector



5 Sheets-Sheet 1 F. B. STARK CABLE CONNECTOR Jan. 10, 1967 Filed Sept.18, 1964 F. B, ...STARK CABLE CONNECTQR Jan. 10?, 1967 5 Sheetsheet 2Filed Sept. I8, 1964 Jan. l0, 1967 F. is.` STARK 3,297,978

CABLE CONNECTOR Filed Sept. 18, 1964 5 SIxeets-Shee 3 I N VEN? UR.

FRANK BENJAM m STARK Jan. 10, 1967 F. B. STARK 3,297,978

CABLE CONNECTOR Filed Sept. 18, 1964 5 Sheets-Sheet i INVIiN'UR.

FRANK BENAAMIN STARK BY anni, 777W 54M,

Jan. l0, 1967 F. B. STARK 3,297,978

CABLE CONNECTOR v Filed Sept. 18, 1964 5 Sheets-Sheet 5 [N VENTR.

FRANK Bim/mm STARK BY gum@ 7W uw United States Patent @dice 3,297,978Patented? Jaa. in, rae? 3,297,97s CABLE CNNECTOR Frank Benjamin Stark,Wormleysburg, lPa., assigner to AMP Incorporated, Harrisburg, Fa. FiledSept. I8, i964, Ser. No. 397,397 2 tlaims. (CI. 339-3177) This inventionrelates to a cable connector of improved construction and particularlyto a connector construction adapted for use with smaller sizes ofshielded and coaxial cable..

It is an object of the invention to provide a shielded and coaxial cableconnector having features which facilitate assembly and manufacture ofrelatively small components.

It is a further object of the invention to provide a cable connectorfeaturing a novel dielectric insert which is readily assembled andanchored within the connector and which serves to anchor the central pinmember thereof in a new way,

It is another object of the invention to provide a novel dielectricinsert construction for coaxial or shielded connectors.

The prevailing practice used in the manufacture of coaxial or shieldedcable connectors calls for an outer metallic shell member which servesas the outer coaxial conductor or shield, a dielectric and pinsupporting insert secured within the shell and a center conductive pinmember which serves as the center conductive path of coaxial andshielded devices.

Typically, the insert is made up of a number of separate molded ormachined pieces of different ydiameters which are individually stackedwithin the conductive shell and secured therein by dimples orindentations placed in the shell after the inserts are properly aligned.Also, typically the center pin member, either before or after beinsoldered or crimped to the center conductive lead of the cable, iswedged or forced within the dielectric insert to a proper position ofalignment. Both of these steps are expensive and both requireconsiderable hand labor. Because of the number of parts used and becauseof the accumulation of tolerances and inexactness of such assemblyprocedures a large number of the connectors turn out to be faulty duringquality control checks, or, even worse, in actual use. The use of forcedcentral pin members which employ flanges, tangs or barbs to anchor themembers against axial displacement invariably results in damage to thedielectric insert.

The foregoing problems are aggravated as the size of the cable andconnector therefor is reduced and in the subminiature ranges which mayhave center pin members of diameters on the order of twenty-fivethousandths of an inch and dielectric inserts of diameters of the orderof a hundredth of an inch, these problems have resulted in a generallyunsatisfactory product.

The connector construction of the invention attains the foregoingobjectives and overcomes the foregoing problems through the use of adielectric insert which is molded in one piece with a rear andnon-complex insulated portion being solidly formed and with a forwardand relatively complex portion being formed in two halves hingedtogether along a common line. Recesses are provided in the forwardportion to lock the center pin member and captivate such upon the halvesof the insert being folded together and inserted within a shell memberof the connector. With this approach, a rather exact assembly ofconnector components may be easily accomplished with little of the riskof misalignment possible with the various parts heretofore required.Because of this a connector which is superior electrically andmechanically to that heretofore available is provided.

In the drawings:

FIGURE l is a plan view showing plug and receptacle connector halvespositioned apart but in alignment for assembly, such halves beingterminated to shielded cables;

FIGURE 2 is a longitudinal section of the connector halves of FIGURE 1joined to provide a connection of cables; v

FIGURE 3 is a perspective of the plug half of the connector of theinvention;

FIGURE 4 is an exploded and perspective View of the connector of FIGURE3;

FIGURE 5 is a perspective of the receptacle of the invention;

FIGURE 6 is an exploded and perspective view of the connector of FIGURE5;

FIGURE 7 is a plan view of the dielectric insert of the plug half of theconnector of the invention;

FIGURE 8 is an end-on elevation of the insert of FIGURE 7;

FIGURE 9 is a side elevation of the insert of FIG- URE 7;

FIGURE l0 is a plan view showing the outer conductive member of the plughalf of the connector of the invention with the insert of FIGURES 7, 8and 9 inserted and positioned therein;

FIGURE ll is a plan view of the insert 0f the receptacle half of theconnector of the invention;

FIGURE 12 is an end-on .elevation of the insert of FIGURE ll;

FIGURE 13 is a side elevation of the insert of FIG- URE l1;

FIGURE 14 is a plan view of the receptacle half of the connector of theinvention showing the dielectric insert of FIGURES ll, l2 and 13positioned and secured therein; and

FIGURE l5 is a perspective of the procedure employed to assemble thereceptacle of the invention.

Referring now to FIGURE l the plug half Ztl of a coaxial shieldedconnector is positioned for insertion and mating with a receptacle half32. Half 32 includes in the embodiment shown, means to secure such halfto a panel I9. By plugging 20 into 32 and threading the outer shellthereof over the threading of 32, coaxial or shielded cables are joined.Thus, in FIGURE 2 with the connector halves mated together, the innerand outer conductive paths of cables )lil and 10 are electrically andmechanically connected. Each of the cables may be seen in FIGURE 2 toinclude, referring to cable half It), a center conductor I2, adielectric sheath I4, an outer conductor 16 and a protective outersheath 18. The outer conductive path 16 is joined to the opposite cablethrough a conductive shell of Ztl to a conductive shell of 3d. Thecenter conductive path is extended from the end of I2 via a central pinmember in 20 and its contact with a male pin member in connector half 32to the central conductor 12.

FIGURES 3 and 5 show among other things, the technique of termination tothe cable outer conductor and such is substantially identical in bothplug 2t) and receptacle 32 to include a metallic ferrule 26 positionedover a rear extension of the connector half and crimped inwardly as at26a and 26h. The crimp 26a serves to force the conductor I6 intoengagement with the outer surface including small serrations as shown inFIGURE 2, of the extension 22d of shell 22 and the crimp 26b serves toprovide cable support. The center pin members of each half are attachedto the conductor l2 by a crimp shown in FIGURE 2 as 30b applied to pinmember 30; a similar crimp being applied to the pin 44 of half 32.

In FIGURES 2, 3 and 4 the detailed construction of the plug half of theconnector of the invention can be seen. The shell member 22 includes acentral barrel or shell 22a having a pair of apertures 2lb thereinadapted to facilitate entry of crimping dies for the crimping operationof the central pin member. Adjacent the rear portion of 22a is an outertiange 22C suitably threaded to accommodate the interior threading ofplug sleeve 24. To the rear -of 22e is the extension 22d which serves toaccommodate the crimping ferrule in its termination of the cable outerconductor I6. Forwardly of 22a is a sleeve of reduced diameter 22e whichdefines a bore 22f extending through the shell. The outer sleeve 24- isadapted to fit up over the shell as indicated in FIGURES 2 and 3 and isprovided with knurling shown as 24e to facilitate threading theconnector onto the receptacle half 32. The crimping ferrule 26 iscrimped inwardly over the braid and over 22d as described.

Included Within 22 is a dielectric insert 28 which extends from a pointof protrusion defined by the beveled flange 28a back through the shellinto and through the bore of 22d. The insert 2S includes a body 2SChaving an aperture 28d therethrough to permit entry o f the crimpingdies which are inserted through 22b of 22. Extending from the body is asleeve portion 28e which tits in against the inner surface of 22d andhas an inner bore adapted to accommodate the dielectric sheath of thecable shown as 14 in FIGURE 2. The forward beveled end 28a includesslots 28b which have a function to be described relative to thereceptacle and FIGURE 15. Insert 28 houses and captivates a pin member39 against axial displacement relative to the assembly. This pin memberincludes a forward bifurcated spring portion 30a, a body portion 3011and a flange 30C which is entrapped within 2S as indicated in FIGURE 2.

The receptacle 32 is comprised as indicated in FIG- URES 2, and 6 of ashell 34 having a central body portion 34a threaded as at 34h and havingflats provided thereon as at 34d. The threading 3411 is relieved in thecenter as at 34C to reduce the thickness of the shell for reasons to becovered hereinafter. To the rear of the threaded portion of 32 is atiange 34e whech serves to lock the connector half within the board 19as indicated in FIGURE 1 and to the rear of 34e is an extension 34)which serves to accommodate the forward portion of the ferrule 36 in itstermination to the cable outer conductor. A locking washer 3S and a nut40 are shown positioned on the receptacle in FIGURE 5 and such serve thefunction shown in FIGURE 1, A dielectric insert 42 is provided whichfits within the shell 34 in the manner shown in FIGURE 2. The insert 42includes a body portion 42a, a central aperture 2b and a relatively fiatforward face 42C. A rear portion 42d is provided which fits down within34f of the sleeve extension and has an inner bore to accommodate thedielectric sheath of the cable. Slots 42b are provided in the face 42Chaving a function to be described. A central pin member 44 is fittedwithin and captivated by insert 42; this pin member includes a forwardportion 44a adapted to iit within 30 as in FIGURE 1 and a rear flangei4-b which cooperates with 42.

As can be visualized from the plug and receptacle engagement depicted inFIGURE 2, the pin members each include well dened flange surfaces whichare fitted into recesses of the dielectric inserts of each connectorhalf. This is accomplished without the damage to the insert materialtypically occasioned with prior art devices by a forced insertion of thepiu within the insert.

Viewing FIGURES 7, 8 and 9, the insert for the plug half is shown in anopen position as it appears following production. Preferably, the piece28 is molded of material having dielectric characteristics such aspolypropylene. The forward portion, beginning with the beveled nose 23ais formed in two halves such that both the interior and exterior can bemade in the flat. The rear portion 23e is formed full round or solid andis joined at the forward portion by a flange Zf which dares to theclosed diameter of the forward portion. The forming of the rear portionsolidly is preferred to better support the dielectric during assemblyinsertion and to provide a the center conductor of the cable.

smooth surface of entry for the cable dielectric to prevent such frombeing inadvertently pulled back off of Furthermore, in the subminiaturesizes, the relatively thin walls of 28e, in conjunction with its length,make a solid piece desirable from a standpoint of structural integrity.To the rear of the beveled end 28a in each half is a recess 281" whichserves to accommodate the spring portion 39a of the center pin Contact,a pin support portion 23h formed by a Vrecess of lesser diameter and arelieved portion 23d which forms the other half of an aperture to permitcrimping of the center pin contact. To the rear of 23d is a furtherrecessed portion 2Sg accommodating the volume of the pin flange which ismade to lit snugly therewithin. The upper half is substantiallyidentical to the lower half and is hinged thereto by webs 28k and 231with a relief portion therebetween which forms the opposing aperture fordie entry into the point wherein the pin is crimped. Extending withinthe beveled portion are slots 28d to accommodate a forked member shownas F in FIGURE 15, which is utilized to orient the insert with respectto the crimping aperture 22]) and shell 22.

In assembly the insert is folded together around the center pin member30 and is inserted within the shell 22 with the forked member F beingmanipulated to twist the insert into proper position of alignment withrespect to apertures 221:. In this position a further member H isbrought down through the aperture 22b to hold the center pin in positionand small indentations are made around the periphery of the shell 22,such being shown as 22g, which lock the insert to the shell and inposition. Thereafter, the cable is inserted with the braid drawn up over22d of the shell and the inner conductor inserted within the center pinmember with the crimps then being applied to the pin and ferrule.

FIGURES 11-14 show a similar part for the receptacle to include aninsert 42 having a forward portion 42a faced as at 42C and recessed asat 4.2i to accommodate the pin member of such half. A rear recess 42g isprovided in each of the halves of the forward portion to hold the pinflange 5b and webs 42k and 421 are provided which hold the two halvesstructurally together. The rear portion of the insert includes a sleeve42e which joins the forward portion through a flange 421i In a similarmanner the forward portion 42a is provided with slots 42b whichcooperate with the tynes of F for insertion in orientation of the insertin the shell 34 of the receptacle connector half. The relieved portion34e heretofore discussed in the threading 34h permits a metal thinnesssufficient to accommodate staking or indentations shown as 341' to lockthe insert within the receptacle shell in the same manner asindentations 22g in the connector plug half.

Thus, with respect to halves 2t) and 32 each is provided with an insertwhich includes a halved forward portion to permit housing or captivationof the central pin member without forced insertion which will damage theinsert material. Further, by the provision of the insert recesses whichcooperate with surfaces of the pin members, the pins are secured againstaxial displacement and adequately supported in an aligned position. Thesolidly formed rear portions of each of the inserts serve as an aligningmeans so that the insert is properly secured within the shell andfurther serve to guide the cable dielectric into a proper position andto insulate the center conductor from the connector shell.

Changes in construction will occur to those skilled in the art andvarious apparently different modifications and embodiments may be madewithout departing from the scope of the invention, The matter set forthin the foregoing description and accompanying drawings is offered by wayof illustration only.

What is claimed is:

1. In a connector assembly for use with coaxial cable of the type havinga center conductor surrounded by a dielectric sheath and an outerconductor, the combination comprising a pair of connector halves eachcomprised of an outer tubular member of conductive material having abore extending therethrough, a dielectric insert tted therein and acenter contact member held in said insert, said center contact memberincluding `a bore to receive the cable center conductor, the forwardportion of said halves being adapted for intermating and the rearwardportion of said halves being adapted to be fitted beneath the outerconductor of the cable and terminated thereto by a ferrule applied oversaid outer conductor and over said rearward portion, the said lrearwardportions having an inner bore less in diameter than that of the bore ofthe said forward portions, each of said dielectric inserts being adaptedto be inserted from the forward portion of each half into each half,each insert including a rearward portion of an outer diameter to befitted into the rearward portion of the tubular member of each half,said rearward portion of said insert being solidly formed into a sleeveconfiguration having an outer diameter to engage theinner surface of therearward portion of the tubular member and an inner diameterapproximating the diameter of the dielectric sheath of the cable, eachof said inserts having adjacent the said rearward portion a forwardportion comprised of two halves hinged on one side and adapted to befolded together to form a configuration to tit within the forwardportion of the tubular member of each half and be supported by the innersurface thereof, the said halves of the forward portion of the insertincluding receses adapted to receive a said center contact member andsupport said center contact member centrally Within said tubular memberand to captivate `such member against axial displacement when the halves`of said insert are folded together and said insert is inserted within aconnector half tubular member, the said insert serving to support andguide the insertion of the coaxial cable dielectric sheath and centerconductor within said tubular member and lto guide the center conductorwithin the center contact member thereof.

2. The assembly of ,claim 1, wherein the tubular member of eachconnector half includes at least two crimping ports spaced apart andeach insert includes a relief extending therethrough including theportion defining the hinge of the two halves of an insert which whenaligned with said ports permits insertion of crimping dies within saidconnector half to crimp said center contact member to the cable centerconductor.

References Cited by the Examiner UNITED STATES PATENTS 1,078,586 11/1913Knaui 339-210X 1,910,306 5/1933 Pullon 339-210X 3,144,292 8/1964 Forney339-276 X 3,221,290 11/1965 Stark et al 339--177 FOREIGN PATENTS 767,3331/1957 Great Britain. 924,920 5/ 1963 Great Britain.

EDWARD C. ALLEN, Primary Examiner. W. DONALD MILLER, Examiner.

1. IN A CONNECTOR ASSEMBLY FOR USE WITH COAXIAL CABLE OF THE TYPE HAVINGA CENTER CONDUCTOR SURROUNDED BY A DIELECTRIC SHEATH AND AN OUTERCONDUCTOR, THE COMBINATION COMPRISING A PAIR OF CONNECTOR HALVES EACHCOMPRISED OF AN OUTER TUBULAR MEMBER OF CONDUCTIVE MATERIAL HAVING ABORE EXTENDING THERETHROUGH, A DIELECTRIC INSERT FITTED THEREIN AND ACENTER CONTACT MEMBER HELD IN SAID INSERT, SAID CENTER CONTACT MEMBERINCLUDING A BORE TO RECEIVE THE CABLE CENTER CONDUCTOR, THE FORWARDPORTION OF SAID HALVES BEING ADAPTED FOR INTERMATING AND THE REARWARDPORTION OF SAID HALVES BEING ADAPTED TO BE FITTED BENEATH THE OUTERCONDUCTOR OF THE CABLE AND TERMINATED THERETO BY A FERRULE APPLIED OVERSAID OUTER CONDUCTOR AND OVER SAID REARWARD PORTION, THE SAID REARWARDPORTIONS HAVING AN INNER BORE LESS IN DIAMETER THAN THAT OF THE BORE OFTHE SAID FORWARD PORTIONS, EACH OF SAID DIELECTRIC INSERTS BEING ADAPTEDTO BE INSERTED FROM THE FORWARD PORTION OF EACH HALF INTO EACH HALF,EACH INSERT INCLUDING A REARWARD PORTION OF AN OUTER DIAMETER TO BEFITTED INTO THE REARWARD PORTION OF THE TUBULAR MEMBER OF EACH HALF,SAID REARWARD PORTION OF SAID INSERT BEING SOLIDLY FORMED INTO A SLEEVECONFIGURATION HAVING AN OUTER DIAMETER TO ENGAGE THE INNER SURFACE OFTHE REARWARD PORTION OF THE TUBULAR MEMBER AND AN INNER DIAMETERAPPROXIMATING THE DIAMETER OF THE DIELECTRIC SHEATH OF THE CABLE, EACHOF SAID INSERTS HAVING ADJACENT THE SAID REARWARD PORTION A FORWARDPORTION COMPRISED OF TWO HALVES HINGED ON ONE SIDE AND ADAPTED TO BEFOLDED TOGETHER TO FORM A CONFIGURATION TO FIT WITHIN THE FORWARDPORTION OF THE TUBULAR MEMBER OF EACH HALF AND BE SUPPORTED BY THE INNERSURFACE THEREOF, THE SAID HALVES OF THE FORWARD PORTION OF THE INSERTINCLUDING RECESES ADAPTED TO RECEIVE A SAID CENTER CONTACT MEMBER ANDSUPPORT SAID CENTER CONTACT MEMBER CENTRALLY WITHIN SAID TUBULAR MEMBERAND TO CAPTIVATE SUCH MEMBER AGAINST AXIAL DISPLACEMENT WHEN THE HALVESOF SAID INSERT ARE FOLDED TOGETHER AND SAID INSERT IS INSERTED WITHIN ACONNECTOR HALF TUBULAR MEMBER, THE SAID INSERT SERVING TO SUPPORT ANDGUIDE THE INSERTION OF THE COAXIAL CABLE DIELECTRIC SHEATH AND CENTERCONDUCTOR WITHIN SAID TUBULAR MEMBER AND TO GUIDE THE CENTER CONDUCTORWITHIN THE CENTER CONTACT MEMBER THEREOF.